Spent battery waste and the wastewater generated during its recycling are two important sources of metals such as Al, Li, Co, Ni, and Mn, etc. BETTERyRec project proposes the integration of biotechnological approaches in the traditional battery recycling flowsheet to increase the efficiency and eco-friendliness of the process through a novel use of biosurfactants as flotation reagents in ion flotation process i.e. bioionflotation. The main goals of the project are to optimize and scale up a novel bioleaching process for metal recovery from solid fractions of battery waste; develop a key bioionflotation process for metal recovery from dilute battery recycling water; and their integration into traditional flotation and leaching methods, followed by metal recovery in pure forms and production of battery grade materials. The project fits well with the complimentary scope i.e. Waste to Wealth campaign of India’s interest and accommodates critical metal recovery, circular economy and Research and Innovation projects on Battery Raw Materials focus for Germany’s strategic initiatives.
Moldedfiber packaging (MFP) made from natural fibers finds diverse applications, but for direct food contact, it traditionally relies on virgin fibers. The challenge lies in incorporating functional barriers, such as those against grease, typically achieved through additives derived from fossil raw materials, compromising packaging recyclability. This research project introduces an innovative approach, utilizing vegetable residuals from the agricultural industry for both fiber raw material and biogenic additives. Specially treated, highly fibrillated fibers can serve as an effective barrier against grease and oxygen. However, the dewatering and drying processes for this fiber layer require substantial effort and energy, affecting the productivity of the moldedfiber process. In addition to optimizing pulping processes, the project focuses on developing a spray application for these fibers onto a preformed porous fiber network. This innovation aims to streamline the application of fiber-based barrier materials from various waste streams, ensuring a balance between protective function, recyclability, and a favorable environmental footprint as assessed by life cycle analysis (LCA).
Rigid pavements are long-lasting and preferable. However, high-volume utilization of naturalmaterials makes this choice unsustainable and expensive. The use of construction, demolition, andindustrial wastes can induce sustainability and economic benefits in rigid pavements. This projectexplores the potential of locally sourced waste streams in India and Germany to be used asconstituents in concrete replacing both Portland cement and natural aggregates in high volumes atthe same time. Scientific knowledge on microstructure and properties of concrete with such highvolume of waste materials will be developed to address key challenges such as processing of waste,activation of waste materials (carbon and thermal activation), dimensional stability (creep,shrinkage, and curling) and durability (Alkali-silica reaction, freeze-thaw, and leaching).Mechanistic models will be developed to enable design of pavements utilizing such materials and aholistic machine learning based mix design framework which also considers life cycle assessmentdeveloped will help to maximize use of locally sourced waste streams. The final demonstrator willensure the field applicability of the developed framework with an aim to reach TRL6 at the projectend. The partnerships established in this project between academic institutions and industry inIndia and Germany will lead to a long-term impact on the practice of sustainable construction andalso in drafting the policies to enable the same.
The current strategies for reusing reclaimed asphalt pavement (RAP) are limited due to the lack of understanding of the extent of the recyclability of bitumen. Hence, the proportion and grade of virgin bitumen, the use of the rejuvenator, and its dosage are based on trial and error. This study attempts to evaluate the extent of recyclability in RAP bitumen by analysing its chemical composition and rheological properties. The possibility of using various crude oil base fractions as an alternative to virgin bitumen and rejuvenator is explored. To ensure that one can maximise the use of RAP, the uncertainty associated with the degree of blending at the mixture level is circumvented by proposing a unique approach to isolate bitumen from RAP. This study, hence, proposes two novel concepts, quantifying the extent of recyclability of bitumen in RAP and the use of a novel processing concept on an industrial scale to enable the highest possible recovery level of the individual fractions of the RAP.
High-quality recycling of metals requires the sorting into pure alloy fractions. To process theaccruing quantity of aluminium scrap a rapid analysis method is needed. In principle, this can beachieved with laser-induced breakdown spectroscopy (LIBS). In practice, a limiting factor is thethroughput of material presented to the LIBS sensor. To overcome this, a novel multiplexing 3DscanningLIBS sensor is being developed. A multiplexing fiber laser source with high repetition ratewill feed an array of laser scanners that cover a large conveyor belt area on which the pieces passby. The LIBS signal will be observed with a spectrometer at high rate. This approach requires theadaptation of novel laser source, scanner and spectrometer technologies to the advanced LIBSrequirements. A demonstration system will be set up to show the suitability for a high-throughputapplication. The system will be tested with aluminium scrap and its extension to an industrial scaleplant will be examined.
This proposal promotes sustainability and circular economy by reprocessing industrial silicon nitride(Si3N4) and silicon carbide (SiC) waste using Polymer Derived Ceramic (PDC) technology. Thistransformative method aims to address the mass market through conventional forming processsuch as – Uniaxial pressing, Isostatic pressing, slurry casting and cater to special products by additivemanufacturing (3D-Printing) technique. It is also envisaged to develop feed stocks using PDCmodified wastes for additive manufacturing that can help create an independent ecosystem withinthe framework of additive manufacturing of materials. State-of-the-art advanced characterizationtechniques will be used to unveil & evaluate the chemistry and microstructure of the recycledproducts coupled with comprehensive thermo-mechanical analysis to assess the product reliability.We affirm the performance of recycled products through meticulous testing and validation inindustries for potential product development, thus promoting waste-to-resource conversion andfostering a greener future. This comprehensive project aligns with circular economy principles,presenting an innovative solution to address industrial waste while paving the way for a moresustainable and efficient industrial landscape.
Presently used metallic bioimplants are non-degradable and remain permanently inside the body necessitating secondary surgery for removal. To overcome such problems, biodegradable (BD) metallic implants (Fe-Mn, Mg, Zn) are being developed. Mg based alloys are recently being commercialized for dental, trauma and orthopaedic applications. However, their usage is not extended to the applications which require longer period due to higher degradation rates and hydrogen evolution. These can be reduced by incorporating fine grain structure and coatings. Fe-Mn based alloys are recently gaining importance due to high specific strength and low cost. The challenge with Fe-Mn based alloys is lower degradation rates which can be addressed by miniaturizing. Presently, these BD implants are being developed by conventional techniques. Additive manufacturing (AM) is an advanced manufacturing technique that makes complex and custom made components with fine grained structure, controlled porosity and degradation rates. In addition, the challenges in fabrication of Mg based implants due to issues with forming and machinability can be overcome by AM. The reported studies on AM are preliminary. The use of soft tissue anchors (STA) as implants is projected to increase due to wider usage for fixing sports injuries as well as repairing wear and tear of tendons, ligaments and cartilage. This study envisages design of STAs, development of Mg and Fe-Mn alloy powders with suitable composition and demonstration of AM process for the manufacture of prototypes. It also involves characterization (microstructural, mechanical and biological) of AM built and surface modified coupons as well as components.